product & applications catalog 2011fedco-usa.com/sites/default/files/fedco catalog 2011...
TRANSCRIPT
Copyright ©2011 Fluid Equipment Development Company, LLC REV3.v4-A-08/11
HP Feed Pumps and Energy Recovery Boostersfor Brackish Water and Seawater RO Applications
Fluid Equipment Development Company, LLC
Product & ApplicationsCatalog 2011
HPB LPH MSS
SSD MSB HP-HEMI
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FEDCO designs everyproduct it o!ers
Your Single Source forPumps and Energy Recovery Systems
Every dimensionaltolerance is checked
Integrated manufacturingeliminates potential errors
Every unit isperformance tested
Fluid Equipment Development Company (FEDCO) was founded in 1997 to develop new !uid machinery to reduce the cost of reverse osmosis desalination. The results included patented concepts, highly integrated design and manufacturing software, and sophisticated manufacturing processes.
That e"ort culminated in multiple lines of energy recovery turbines and pumps uniquely suited for seawater and brackish RO desalination.
With the longest warranty and the highest e#ciencies, FEDCO's product lines are unmatched in quality and performance by any manufacturer in the RO equipment market. FEDCO is a widely recognized supplier with thousands of units installed around the world.
COMMITTED TO SUCCESS
We know RO. FEDCO equipment is designed and built to meet the speci$c challenges of seawater and brackish water RO applications.
FEDCO knows the importance of e#ciency, reliability, low capital cost and the importance of easy operation. We know what it takes for OEMs and end users to make money from their RO systems.
800 Ternes DriveMonroe, MI 48162 USA
Fluid Equipment Development Company, LLC
Tel: +734.241.3935 Fax: +734.241.5173
Customer trainingensures optimal results
About FEDCO
3
About FEDCO
About FEDCOFounded in 1997 as a partnership between Osmonics, Inc. and Eli Oklejas, FEDCO’s goal was to develop innovative high pressure pumps (HPP) and energy recovery devices (ERD) for BW and SW RO systems. General Electric became FEDCO’s partner from 2003 through 2006. Today, FEDCO is 100% privately owned and remains focused on innovation, quality and cost-e!ective solutions for pumping and energy recovery.
The FEDCO AdvantageOur teams of talented and energetic engineers, manufacturing specialists and systems experts have created a fully integrated enterprise with one aim - to provide our customers with customized "uid machines with exceptional e#ciency and low capital cost coupled with customer service that exceeds their expectations. The results include new designs, technology, manufacturing processes, and standards.
Our Design - Focused on Membrane SystemsFEDCO designs "uid machines to take full advantage of the technical characteristics of the membrane process. FEDCO pumps only cover "ows and pressures found in BWRO and seawater SWRO applications. They are designed for clean "uids and are optimized for typical suction pressures in RO systems. Our ERDs include variable area nozzles that meet typical brine pressure variations. Our products eliminate external tubing carrying high pressure feed or brine that can fail creating hazards to personnel and equipment. Our units are designed for operation and maintenance by unskilled personnel in the harshest of desert or marine environments.
Our pumps and ERDs use bearings that are lubricated by feed or brine to eliminate the numerous maintenance and logistics issues associated with oil or grease lubricated bearing systems. FEDCO o!ers three material of construction: Duplex SS, Super Duplex SS and 316 SS.
Our TechnologyYears of continuous improvement driven by customer feedback have lead to key technical developments in FEDCO pumps and ERDs.
WATER BEARING™The WATER BEARING™ eliminates virtually all pump bearing maintenance and numerous failure modes associated with oil/grease lubricated bearing systems. The WATER BEARING™ absorbs the high levels of thrust generated by centrifugal pump operation by using a balance disc integrated into the discharge of the pump housing. The pumpage (e.g. feed water) provides all lubrication and cooling. Moreover, by locating the WATER BEARING™ in the pump discharge, thrust loads act to place the pump shaft in tension. The WATER BEARING™ is standard on the MSS, MSB, MSD, SSD, and LP product lines.
1 Absorbs all thrust generated by pump operation - zero thrust to the motor2 Uses pumpage to cool the bearing - no ambient temperature limit3 Entirely housed within pump shell - immune to dust, sand and grit4 Lubricated entirely by the feed - never needs lubrication5 Zero maintenance - provides years of uninterrupted service6 Unique layout places pump shaft in optimal tension - no potential for shaft buckling7 Easy Inspection - no distrubance to motor, coupling or alignment
TECHNOLOGY
PATENTED
2
1
3
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5
7
!
A shaft in compression is more likely to bend causing impeller misalignment.
A shaft in tension is more stable and runs truer than a shaft in compression.
MOTOR
CONVENTIONAL THRUSTBEARING
WATER BEARING™
IMPELLER SHAFT
THRUST
4
About FEDCO
ROTOR-FLO™ Lubrication This patent-pending design provides optimal lubrication to the rotor thrust bearing using feed water as the lubricant. The design was developed to meet system startup procedures where membranes, headers and associated piping partially drain during shutdown. This could result in momentary operation with a dry thrust bearing during start-up. The ROTOR-FLO™ design ensures full lubrication at the instant of start-up. Moreover, the radial !ow channels, automatically increases bearing pressure as rotor speed (and thrust load) increases.
The ROTOR-FLO™ design is used in the HPB and HP-HEMI product lines. The ROTOR-FLO™ design eliminates external lubrication lines and "ttings (used in competing units) thus ensuring maximum reliability and safety. The ROTOR-FLO™ is standard on all HPB and HP-HEMI models.
Customized Hydraulic DesignThe hydraulic !ow channels in a !uid machine determines e#ciency, pressure generation and !ow range. Every FEDCO HPB, SSD, HEMI, and LP turbine module is designed with customized impeller geometry, multi-vane di$users, turbine volutes, and nozzle rings.
“catalog” units with poorly matching hydraulic performance and reduced e#ciency, facturing process, no waiting for castings, no delays in overhaul kits even years after original installation.
CFD AnalysisComputational Fluid Dynamics (CFD) has become a standard tool in advanced pump design e$orts. Yet, to turn millions of calculations into pump and turbine hardware that perform as predicted takes years of focused research, hundreds of accurate hydraulic tests and continuous re"nement of the CFD model parameters.
Comprehensive CFD analysis guides the custom design of all hydraulic passages for every mega-HPB ERD and SSD pump. CFD analysis calibrates our proprietary hydraulic design software used for every FEDCO standard product. There is a CFD/testing design basis for every FEDCO unit, backed by years of testing and re"nement.
Integrated Manufacturing OperationsFEDCO developed and continuously re"nes an integrated manufacturing operation that converts customer !ow and pressure requirements into optimized hydraulic designs and then into Computer Numerical Control (CNC) maching programs with little more than a push of a button. The resulting designs represent the most advanced hydraulic designs and machining optimization in our market.
The CNC programs and work instructions are sent to the manufacturing machines via a computer network. Often, within hours of order entry, fully customized and optimized pumps and turbines are being manufactured from the speci"ed stainless steel alloys.
Customized components are tracked through the manufacturing process. All test data is acquired through data acquisition systems with results saved on data servers.
FEEDIMPELLER
FLOW CHANNEL
RADIAL CHANNEL
THRUSTBEARING
BRINEIMPELLER
ROTOR SHAFT
ROTOR-FLO™ LUBRICATION CHANNELS
5
About FEDCO
Standards and ProcessesISO-9001- Registration will be achieved in August 2011
ISO-14001 - Registration will be achieved in August 2011
CE Mark - Available on most FEDCO product lines
NSF test loop certi!cation - Large production test loops have received NSF certi!cation for compliance with Hydraulic Institute test standards for centrifugal pumps.
In addition to CFD software, FEDCO utilizes a wide variety of design and analytical software including:
stress/strain levels
minimize the potential for casting defects such as porosity and shrinkage
Product TestingTying together analytical designs, prototype development and production testing,
FEDCO tests 100% of all production units.
Production test loops are certi!ed by NSF to meet Hydraulic Institute Standards for centrifugal pump testing.
FEDCO FacilitiesFEDCO operates from a 5,500 m2 facility owned by FEDCO and built to its speci!cations. The !rst phase was completed in 2006 and a second phase more than doubled the size
and training areas and a data center.
Located in the heart of the industrial area of the United States, FEDCO has full access to the latest in production and measurement technology. The local labor force is highly trained in all aspects of manufacturing technology and processes.
Overhead cranes ensure safe and e"cient handling of components as well as complete assemblies.
The entire facility is air conditioned and heated using highly e"cient geothermal heat
whenever feasible to recover spilled water when test loop piping is recon!gured.
ISO-14001 helps ensure that FEDCO seeks continuous improvement in its environmental and safety responsibilities.
FEDCO welcomes customers to inspect is facilities and operations.
6
MSS SERIES HP FEED PUMP7 - 270 m3/hr (30 - 1200 gpm) and pressures to 83 bar (1200 psi)
MSD SERIES HP FEED PUMP100 - 450 m3/hr (440 - 1980 gpm) and pressures to 69 barg (1000 psig)All Duplex SS 2205 construction
HYDRAULIC PRESSURE BOOSTER (HPB) ENERGY RECOVERY TURBINE10 - 450 m3/hr (30 - 1980 gpm)Pressures to 83 barg (1200 psig) with option up to 110 barConstructed in Duplex SS 2205 or Super Duplex 2507
SSD SERIES HP FEED PUMPSingle stage HP feed pumps for SWRO service
Up to 1700 m3/hr (7500 gpm)Pressures to 80+ barg (1200+ psig with HPB or HP-HEMI)Direct drive - 3500 RPM or 2900 RPM nominal speed
HP-HEMI AND HPB ERDObtain total control of your membrane operating conditionswith FEDCO's Hydraulic Energy Management Integration (HEMI)for SWRO system.
3200 m3/hr (14000 gpm)Pressures to 83 barg (1200 psig)
MSB SERIES PUMP10 - 250 m3/hr (44 - 1100 gpm) and pressures to 35 bar (500 psi)316 SS construction
LPH, LPS, LPD, AND BPBFEDCO brings a!ordable energy recovery to low pressure RO systems.
30 - 300 m3/hr (130 - 1320 gpm) brine "ow80 - 750 m3/hr (350 - 3300 gpm) feed "owPressures from 6 - 30 barg (87 - 430 psig)316 SS construction
Standard Product Line
Retro#ts
Products and Services
Table of Contents
Mega Systems
Parts & Field Service
Life Cycle Cost Analysis (LLCA)
Brackish Water/Low Pressure Systems
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Standard Products - MSS and MSD Feed Pumps with HPB
/hr
Standard Products
8
Standard Products
MSS Series Feed PumpsThe MSS series multi-stage centrifugal high pressure feed pumps have proved to be the most reliable high pressure feed pump available today.
Loaded with unique features such as the patented WATER BEARING™ thrust bearing, pumpage-lubricated shaft bearings and maintenance-free design ensure years of trouble-free operation.
All MSS pumps can be equipped with a high inlet pressure option to allow inlet pressures to 70 barg. The unique design features:
operating at low pressure (1-2 bars typical)
loads - a major problem with high inlet pressure operation.
HP seal option
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8
9
1
11
4
7
10
6
2
5
3
1 Shaft seal operates at low pressure
2 Flexible disc coupling
3 Bearing drain line (low pressure)
4 316 SS shell support bracket
5 Precision leveling foot
6 Victaulic pipe joints
7 Duplex SS 2205 housing
8 Flanged construction for easy internal inspection
9 Inlet rotatable in 90° increments
10 Easy shaft alignment
11 Integrated motor adapter (anodized aluminum alloy)
12 316L SS stages – passivated & electropolished – proven in hundreds of SWRO applications
13 WATER BEARING™
MODELSMSS-15MSS-20MSS-30MSS-40MSS-50MSS-55MSS-70MSS-75MSS-90MSS-120MSS-160MSS-200MSS-240
TECHNOLOGY
PATENTED
12
9
Standard Products
6
5
1
2
12
HP seal option
The MSD series multi-stage centrifugal high pressure feed pumps provide a new level of reliability and e!ciency in SWRO pumps.
Loaded with unique features such as the patented WATER BEARING™ thrust bearing, all Duplex SS construction, pumpage-lubricated bearings and maintenance-free design ensure years of trouble-free operation.
The MSD series is all Duplex SS 2205 construction (optional Super Duplex SS 2507) with precision investment cast stages and impellers. This unit will feature fast delivery, shipments to start in September 2011.
MSD Series Feed Pumps
All MSD pumps can be equipped with a high inlet pressure option to allow inlet pressures to 70 barg. The unique design features:
operating at low pressure (1-2 bars typical)
loads - a major problem with high inlet pressure operation.
MODELSMSD-170MSD-250MSD-350MSD-500
1 Shaft seal operates at low pressure
2 Flexible disc coupling
3 Bearing drain line (low pressure)
4 316 SS shell support bracket
5 Victaulic pipe joints
6 Baseplate
7 Flanged construction for easy internal inspection
8 Inlet rotatable in 90° increments
9 Easy shaft alignment
10 Integrated motor adapter (anodized aluminum alloy)
11 Duplex SS 2205 stages (Super Duplex SS 2507 optional)
12 WATER BEARING™
TECHNOLOGY
PATENTED
34
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Standard Products
Hydraulic Pressure Boosters (HPB)The World’s Most E!cient Turbine Based ERDPerformance and ReliabilityFEDCO leads the industry in turbocharger e!ciency as the "rst and only company to exceed 80% transfer e!ciency. The same technology used in our record-setting units is used throughout our entire HPB product line.Superior e!ciency comes with superior reliability as FEDCO o#ers the industry-leading three (3) year limited warranty on the entire HPB product line. Our high quality design includes:
and many other features make the HPB the "rst choice for reliability.
Why HPB has the longest warranty in the industry:
EFFICIENCYWhether it is "eld operating log sheet data or precision test
displays the highest
any turbocharger ERD.
and CFD optimized hydraulic design makes the di#erence.
11
Standard Products
With nine (9) models, there is a perfect !t for your most demanding performance, reliability and project schedule requirements. Standard MOC is Duplex SS 2205, however, Super Duplex SS 2507 is optional. Brine nozzle valve actuators, "anged connections and other options available. Delivery of the standard line HPBs are built to your "ows and pressures speci!cations in three (3) to (6) weeks in Duplex SS 2205.
Brine Flow RegulationBrine "ow adjustment is accomplished by simply turning the aux nozzle handle. Open to increase brine "ow and close to reduce brine "ow. Note that the multi-turn needle valve provides precise "ow regulation.
Note that brine is not bypassed when the nozzle is open - all brine "ow passes through the turbine impeller to maximize energy recovery.
1 Variable area in nozzle (needle type for precise control)
2 Nameplate
3 Thrust bearing - patent pending design, allows dry running
4 Brine nozzle and volute - custom designed and machined
5 Brine (turbine) impeller - custom designed and machined
6 Rotor shaft - integral with impellers (no keys, studs, washers, etc.)
7 Center bearing lubricated by feed - ZERO brine leakage to feed
8 Feed (pump) impeller - custom designed and machined
9 End cap
10 Multi-vane di#user - custom designed and machined to ensure radial pressure balance for long wear ring and bearing life, provides higher e$ciency than volutes
11 Mounting foot (varies by model)
12 O-rings - all bearings mounted on o-rings for easy removal
13 Victaulic-type pipe joints ("anged joint optional)
14 Standard Duplex SS 2205 MOC (Super Duplex SS 2507 optional)
15 Can discharge brine at higher pressure for easy brine disposal
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3
45
6
7
89
1011
1213
14
15
Minimum Brine Flow Maximum Brine Flow
HPB Hydraulic Pressure BoosterERD Series Features
MODELSHPB-20HPB-30HPB-40HPB-60HPB-80HPB-120HPB-160HPB-250HPB-350
MSS and HPB in a containerHPB-40
MSS with FEDCO baseplateCompact HPB installation
MSS and HPB on common baseplateHPB with reciprocating HPP
12
Standard Products
Typical MSS Pump and HPB Standard Package Installations
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13
Mega Products - SSD and HPB or HP-HEMI3
Mega Products
14
Mega System
s
Mega Systems SSD Series Feed PumpThe SSD series single-stage centrifugal high pressure pump (HPP) performs just like any heavy-duty SWRO feed pump; but, at higher e!ciency and lower capital cost. And, with faster delivery it is ideal for the most demanding project schedule. The SSD series can reach pressures of 82 bar (1200 psi) when used with the HPB or HP-HEMI energy recovery devices. The direct drive motor can be a 50 or 60 Hz, 2-pole motor with speed of 2900 RPM to 3500 RPM.
Our mega system SSD feed pump is supplied in Duplex SS 2205 or the option of Super Duplex SS 2507. A one-piece shaft is machined from bar stock. The single-stage design provides a small footprint. The SSD series use pumpage-lubricated bearings for maintenance free operation.
1
2
3
5
4
7
8
9
Designed Speci"cally for RO Service
maximum possible e!ciency
1 Centerline mount
2 Feed inlet
3 Feed outlet
4 Duplex SS 2205 (optional Super Duplex
SS 2507)
5 Pump-lifting eye-bolt
6 Pumpage-lubricated bearings
7 Coupling guard
8 50 or 60 Hz 2-pole motor
9 Common base plate
10 Di#user ring-custom machined
11 Impeller-custom machined
12 Seal $ush line
13 Shaft
14 Shaft seal
6
10
11
12
13
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MODELSSSD-500SSD-700SSD-1000SSD-1400
6
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15
Mega System
s
Hundreds of Tests, Years of CFD Analysis Yields Record-Setting E!ciencyThe HPB is the "rst and only turbocharger to achieve 80+% transfer e!ciency. CFD (Computational Fluid Dynamics) runs involving trillions of calculations helped to optimize every inch of the #ow passages.
Proprietary software converted the CFD designs into CNC (Computer Numerical Control) programs to turn Duplex SS or Super Duplex SS plate into ultra-smooth and hydraulically optimal feed and brine channels.
Patent-pending bearing systems ensure reliable operation with minimal bearing losses.
Mega System HPB Design and ConstructionSix (6) models cover the largest current and anticipated SWRO trains. Standard MOC is Duplex SS 2205 with Super Duplex SS 2507 optional. Brine nozzle valve actuators, #anged connections and other options available.
Visualization of #ow data from a CFD analysisRecord-setting HPB-1400 displays 80+% transfer e!ciency
MODELSHPB-500HPB-700HPB-1000HPB-1400HPB-2000HPB-2800
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16
Mega System
s
Hydraulic Energy Management Integration (HP-HEMI)/hr
Typical HEMI PLC Display
Permeate flow too high
Permeate flow too low
Brine flow too high
Brine flow too low
HEMI VFD reduces rotor speed (reduces feed boost)
HEMI VFD increases rotor speed (increases feed boost)
Turbine nozzle area reduced (reduces brine flow)
Turbine nozzle area increased (increases brine flow)
17HP-HEMI SSD Feed Pump
Typical low voltage VFD and PLC for the HP-HEMI
Mega System
sMega System High Pressure Hydraulic
Energy Management Integration (HP-HEMI)Six (6) models cover the largest current and anticipated SWRO trains. Standard MOC is Duplex SS 2205 with Super Duplex SS 2507 optional. Brine nozzle valve actuators, !anged connections and other options available. FEDCO provides the complete HEMI package including motor, VFD and valve actuator.
The HEMI control can be integrated into the plant SCADA or FEDCO can provide a stand-alone PLC. Requiring only two process signals, permeate and brine !ow, the HEMI control system is easy to install and operation is simple and intuitive.
1 Brine aux nozzle actuator2 HEMI motor3 Brine discharge module4 Common baseplate
1
2 3
4
HP-HEMI System for SWRO
1 SSD high pressure feed pump provides constant pressure to HP-HEMI
2 HEMI provides variable membrane pressure
3 High pressure brine
4 Brine to drain
5 Permeate1
2
34
5
MODELSHP-HEMI-500HP-HEMI-700HP-HEMI-1000HP-HEMI-1400HP-HEMI-2000HP-HEMI-2800
18
Mega System
s
Mega Systems Design OptionsFEDCO research into the basic hydraulic response of RO systems operating with variable membrane conditions has lead to two new plant designs that maximize energy e!ciency, simpli"es control, and minimizes capital costs.
*Subject to U.S. and International patent applications
FM
FM
HPB-1000
Boost pump
Central HP pump
HP feed manifold
HP brine adjustment valve
LP feed manifold
HP brine manifold
Feed fill line
Isolation valve
Permeate control
Brinecontrol
FM
FM
PI
PIPI
PI
PS
FM
FM
PI
PIPI
PI
PS
Cleaning valve
PI PSPS PI
The HPB is ideal for three-center design by providing a large capital cost savings, simple control schemes and low speci"c energy consumption.
*Subject to U.S. and International patents applications
Hybrid Centralization Three-Center
Hybrid centralization combines the bene"ts of centralized feed pumping and discrete RO train control. This design permits dynamic addition and removal of trains without interruption of production. The control scheme is simple and permits optimization of membrane conditions on a train-by-train basis.
HPB-700 (retrofit of competitors unit)HPB-1000 in Jeddah, Saudi Arabia
SSD-500 with HPB-500 SWRO FacilitySWRO train with HPB at lower right
HPB-1400 units waiting for crating 19
Mega System
sTypical Mega System Installations
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Low Pressure Products
MSB Series Feed Pumps3
MODELSMSB-15MSB-20MSB-30MSB-55MSB-75MSB-90MSB-120MSB-160MSB-200
2 3
7 8 9
8
9
7
3
2
3
TECHNOLOGY
PATENTED
21
Features
1 2
4
8
9
1
2
49
8
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22
Low Pressure Products
The LPH is revolutionizing pumping and energy recovery in brackish water reverse osmosis (BWRO). The rapid acceptance is driven by simple economics - an ERD is only worth using if the cost of saved energy can quickly o!set the capital and installation costs of the ERD (a quick return on investment or ROI).
The unique modular construction of the FEDCO LP product line allows a few components to be con"gured in dozens of ways to achieve the performance requirements of a wide range of BWRO systems without high capital and installation costs. Maintenance costs are likewise reduced as maintenance spares and procedures are minimized for large installations.
The LPH takes full advantage of the modular concept with two (2) turbine options (LPT), "ve (5) stage options and up to three (3) pump modules (LPS) per LPH. Moreover, the turbine module is custom-designed and manufactured to match the speci"ed range of turbine brine #ow and pressure ranges.
LPH - Low Pressure HEMIHydraulic Energy Management Integration
SWRO ERDs have a much easier task of achieving a good return on investment (ROI). Up to 40 times more brine energy is available per m3 of permeate produced than in a BWRO system. Only an ERD with both a low capital costs and good energy recovery e$ciency can be considered in a BWRO system.
0
4
8
12
16
20
24
28
32
36
40
BWRO
SWRO
MODULES
TURBINELPT-125LPT-250PUMPLPS-90LPS-120LPS-160LPS-200LPS-240
(Up to 3 modules in parallel)
1 TEFC motor, rated for vertical operation and with a VFD
2 Variable brine nozzle for #ow and pressure control
3 316 SS or better material of construction
4 In-line connections for easy installation
5 Integrated water-lubricated bearing absorbs all rotor thrust
6 Base plate - powder coated or paint option
7 Victaulic type pipe joints
8 Turbine nozzle ring and impeller custom-manufactured
9 Rotatable turbine section for piping #exibility
1
2
3
4
5
6
7
8
9
Hydraulic Coverage
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With e!ciency up to 80%, "ows up to 750 m3/hr and pressures up to 35 bar, the LPS is the ideal pump for a wide range of BWRO applications. 316 SS construction meets the most demanding corrosion requirements.
The vertical con#guration and low weight virtually eliminates foundation requirements. Shaft alignment is assured by highly accurate machine #ts of the components.
LPS - Low Pressure Pump BWRO Membrane Supply, Product Transfer, and More
MODELSLPS-90LPS-120LPS-160LPS-200LPS-240
(Up to 3 modules in parallel)
1 Motor - rated for VFD usage, vertical operation, TEFC, NEMA or IEC frame
2 Mechanical seal housing
3 Pump module - up to three (3) in parallel
4 Victaulic style pipe joints
5 Baseplate- powder coated or paint option
6 Thrust bearing - water lubricated
7 316 SS construction
1
2
3
4
6
5
7
Three (3) LPS pump module con#guration
23
Low Pressure Products
Hydraulic Coverage
LPD - Low Pressure Drive Conversion of Brine Hydraulic Energy into Electricity
The LPD turbine generator ERD uses brine hydraulic energy to drive a standard induction motor that acts as a generator to produce electrical energy. Integrated into the unit is a regenerative VFD that regulates the LPD to achieve brine !ow and pressure as required for the desired membrane operating conditions while extracting the maximum amount of electrical energy available from the brine stream. The vertically mount motor eliminates a large baseplate. The shaft alignment is assured by highly accurate machine "ts of the components.
Applications:
TURBINELPD-125LPD-250
1 2 Motor - rated for VFD usage, vertical operation, TEFC, NEMA or IEC frame
3 Mechanical seal housing
4 Turbine module
5 Brine nozzle !ow control
6 Baseplate - powder coated or paint option
7 Thrust bearing - water lubricated
8 9 Victaulic type pipe joints
1
2
3
45 6
7
8
9
24
Low Pressure Products
1 Pretreated feed water
2 Low pressure brine
3 Regen VFD
4 Permeate
5 Brine to drain
1
2
3
4
5
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655$ +55$ 755$ 855$ 955$
BPB Interstage Boosting with LPS Pump
BPB LPS
1st Stage
2nd Stage
1 Low pressure feed from LPS pump
2 1st stage brine
3 BPB raises feed to 2nd stage requirements
4 Low pressure brine
5 Brine to drain
6 Permeate
12
34
5
6
MODELSBPB-ABPB-B
When brine pressure is low and energy costs are modest, it takes an exceptionally e!cient and low cost ERD. The BPB is designed exactly for such applications. The BPB is ideal for a low pressure interstage boost application.
The BPB features a fully integrated energy recovery turbine and pump manufactured using proven components of the MSS and HPB product lines. 316 SS construction meets the most demanding corrosion requirements. The BPB units will be in production by the end of 2011.
BPB - Brackish Pressure BoosterHigh E!ciency and Low Cost Pressure Boosting
1 Victaulic type pipe joints
2 Variable brine "ow control
3 316 SS or better metallic components
4 Turbine module
5 Base plate - powder coated or paint option
6 Pump module
7 Thrust bearing - water lubricated
8 Turbine impeller custom - designed and machined from 316 SS plate
1
2
3
4 5
67
8
25
Low Pressure Products
Hydraulic Coverage
LPD-125 in Spain
LPH with 3 modules in Singapore
LPH-240/125 in Florida, USA
LPH-240/125 in California, USA
Typical Brackish Water or Low Pressure Installations
26
Low Pressure Products
High inlet pressure booster pump with VFD. Boosts pressure and used to control PX rotor rotation.
Membrane
FM1
FM2
HP flow meter
HP feed pump
Isolation valve (3)
Control valve. Provides back pressure to prevent cavitation and control fill/purge rate of rotor passages. A simplified system diagram[1] – special flushing piping, safety interlocks, PX sample ports, etc. omitted for clarity. Indicated flows are approximate.
Residual pressure relief valve
Qb
PX units (1 to 20+)
The Complete PX System
Existing HP feed pump
P TComplete FEDCO PX replacement system
Upgrade Existing SWRO Systems with Modern High E!ciency Pumps and ERDs
Pumps and ERDs are undergoing continuous improvement which is especially true with FEDCO products. Performance considered industry-leading, even a few years ago can be eclipsed by newer designs and improved manufacturing processes.
FEDCO o"ers many ways to revitalize old RO systems to achieve performance rivaling new systems.
Retro#ts - Upgrading High Pressure Feed PumpsReplace noisy and unreliable Positive Displacement (PD) pumps with smooth and quiet FEDCO MSS pumps. FEDCO pumps eliminate: Pulsation dampeners Belts and belt guards Suction stabilizers Sheaves/pulleys Packing and packing leakage Special motors Oil and grease lubrication Unsightly corrosions
Are you satis#ed with your PD pump? Then consider adding a FEDCO HPB as an ERD. The FEDCO unit reduces
pump discharge pressure by up to 50% resulting in a large energy savings, reduction in cross-head and crank
bearing loads, reduction in bearing temperatures, improved valve life and quieter operation.
Retro#ts - Replacing Old Low E!ciency TurbochargersWhy replace an old ine!cient turbocharger with another ine!cient turbocharger? FEDCO’s high e!ciency HPB turbochargers will save more energy and provide a three year (36 months) warranty. Its a smart way to save energy and raise plant reliability.
Retro#ts - Replace Isobaric ChambersIsobaric chambers are noted for good e!ciency, high complexity, daunting maintenance and brine mixing. FEDCO o"ers a package that directly replaces an existing isobaric chamber without disturb-ing the existing HP pump or membrane array. With the FEDCO replacement package, you will enjoy improved permeate quality, quieter operation, reduced maintenance and most important - lower cost permeate!
From this... to this!Typical Isobaric Chamber ERD System FEDCO Isobaric Chamber Replacement Package
Retro#t installation at a power station in India
27
Retro#ts
FEDCO maintains a complete inventory of spares for all of its product lines. Even major components such as rotors for turbochargers can be quickly dispached using FEDCO’s unique “loaner rotor” program for minimal equipment down time.
Since FEDCO machines its HPB, turbine, and SSD rotors from bar stock, in the event a replacement is needed, there is no long wait for castings to be poured and machined. FEDCO can begin manufacture from its extensive inventory of bar stock and plate to provide fast supply of any size rotor.
FEDCO Spare Parts, Training, and Field Service
Spare Parts
FEDCO welcomes the opportunity to train customers on the installation and maintenance of FEDCO equipment. Our classroom and shop training facilities provide a comprehensive training in 2 to 3 days. We also o!er training at customer locations around the world.
Training
Our "eld service personnel know our products and they know RO systems. Some are machinists, PLC programmers and mechanics. When our "eld service specialists study a problem, they look at every aspect to quickly identify the root cause and apply the most appropriate solution.
Field Service
28
Parts & Field Service
A systematic procedure de!ned by Europump and U.S. Hydraulic Institute to evaluate life-time costs of pumping equipment based on all cost factors.
The life cycle costs weighs these factors to determine the optimal investment for an ERD or pump. The LCC tells you how much money you have at the end of the day.
Every cost factor associated with a piece of equipment needs to be considered including auxiliary equipment, engineering and procurement costs, administration costs, etc. In addition the timing of the costs must be considered. For example, the combination of in"ation and the cost of capital (interest charges) must be normalized to a Net Preset Value.
The Best Value in LCCAFEDCO equipment is designed to optimize the LCCA value by providing a balanced combination of excellent e#ciency, low capital costs, single source of supply, reliability, and long warranty.
Cost of Energy
Initial CostsTraining Costs
Installation CostsMaintenance CostsNet Cost of Capital
Down TimeDecommissioning
29
LCCALife Cycle Cost Analysis (LCCA)
An RO plant is a complex hydraulic system with high-pressure pumps, energy recovery devices and membranes. Interactions between these devices are complex. The e!ects of variable membrane pressure brought about by changing feed TDS and salinity as well as membrane fouling add to the complexity.
The result is that the energy consumption measured during operation can be much di!erent from predicted values. And, as the plant ages, energy consumption can sharply deteriorate resulting in a signi"cant change in the cost of permeate.
Know Realistic Energy Estimates Before the Plant Design is Finalized...FEDCO has applied its hydraulic machine performance expertize to develop software that can accurately predict pump and ERD performance in response to changing operating conditions. The detailed predicted performance may be presented in graphic or tabular form.
Don’t Be Surprised by Energy Consumption
1 Allows speci"c pump performance curves to be de"ned or use generic curves with estimated e#ciencies.
2 Motor and VFD e#ciency including part-load e#ciency may be inputted or generic values may be used.
3 Up to forty-eight (48) sets of duty points with time-weighted averages can be speci"ed to cover virtually every operating mode of the plant.
4 Turbochargers, Pelton turbines, and pressure exchangers can be analyzed and compared.
5 All calculations are based on published data or reasonable engineering estimates. All calculations are fully transparent.
6 Data may be expressed in graphic form for easy analysis and data presentations.
30
LCCA
Date:
Com:
3/1/2011
12711_R4System Performance Analysis
copyright © Fluid Equipment Development Company - for authorized users only.
LCC PARAMETERS
LIfe cycle period (years) 20Electric cost ($/kW-hr) 0.3Inflation rate (annual) 0.03Interest rate (annual) 0.07
9.0elcyc ytuDField service rate (USD/day) 950Profit + overhead ($/m3) 2
LCC COSTSCic Initial CostCin Install & Commis.Ce Energy costCo Operating costCm Maintenance costCs Downtime costCd DecommissionTOTAL
HPB152,83231,71615,091,9620132,05314,42623415,423,223
PX311,37574,80014,966,3260450,42630,9132,66615,836,506
This LCC Analysis generally conforms to PUMP LIFE CYCLE COSTS: A Guide to LCC Analysis for Pumping Systemsdeveloped by the Hydraulic Institute and Europump.
Date:
Com:
3/1/2011
12711_R4System Performance Analysis
copyright © Fluid Equipment Development Company - for authorized users only.
HPB COST DATA
Procuremnet (days) 1Design and engr. 1
000,07tsoc tinUFoundation 6,182
280,87LATOT
INSTALLATION COSTSO&M training (days) 1ERD Installation 1Feed and brine piping 8,243Victaulics 1,236
973,11LATOT
MAINTENANCEOverhaul unit cost 23,000Period (years) 6Annual maintenance 950
AVAILABILITYSystem uptime 0.998
MISC ONE-TIME COSTSDecommissioning -1,649TOTAL -1,649
HPP COST DATAInstallation design (days) 3Procurement (days) 2Pump and base cost 70,000Motor 0Contactor or VFD 0Control valve 0TOTAL 74,750
INSTALLATION COSTSO&M training (days) 2HPP Installation 7,507Foundation 11,310TOTAL 20,337
MAINTENANCEOverhaul unit cost 23,000Period (years) 6Annual maintenance 1,100
AVAILABILITYHPP availability 0.995
MISC ONE-TIME COSTSDecommissioning 2,162TOTAL 2,162
Monroe, Michigan USA
[email protected]@fedco-usa.com
www.fedco-usa.com
Tel: +1.734.241.3935 Fax: +1.734.241.5173
Global Service and Sales O!cesFEDCO world headquarters are located in the state of Michigan in the United States. The facility houses our admin- istrative, engineering, manufacturing, and sales departments. Our sta" is committed to the success of our customers. You can reach FEDCO personnel between 8:00 AM and 5:00 PM EST (USA).
Worldwide sales representatives o!ces can be found in: China, Japan, India, Israel, Mexico, Korea, and Spain. The Dubai, UAE sales o!ce o"ers complete sales and service for our customers in the Middle East region. Our sales department, #eld service department, and manufacturers representatives are trained at the factory in installation, maintenance, and repair of FEDCO equipment. With years of experience in RO applications, they possess the broad knowledge and experience needed to ensure a smooth and successful application of our equipment.
FEDCO O!ce
Manufacturer Representative (Check website for current list)
31
Contact FEDCO
Dubai, UAE
[email protected]@fedco-usa.com
www.fedco-usa.com
Fluid Equipment Development Company, LLCWorld Headquarters800 Ternes DriveMonroe, MI 48162 USA
[email protected]@fedco-usa.com
www.fedco-usa.com
Tel: +1.734.241.3935 Fax: +1.734.241.5173